What is Manufacturing Process?

Manufacturing process is basically a complex activity, concerned with people who've a broad
number of disciplines and expertise and a wide range of machinery, tools, and equipment with
numerous levels of automation, such as computers, robots, and other equipment. Manufacturing
pursuits must be receptive to several needs and developments.
Beside above, all the future technicians must understand the basic needs of workshop routines in
terms of man, equipment, material, methods, revenue and other infrastructure conveniences
needed to be placed properly for maximum shop or plant layouts and other support solutions
effectively regulated or positioned in the field or industry within a properly planned
manufacturing firm.

Joining
Every joining approach has particular design needs, while certain joint needs may propose a
particular joining approach. Design for assembly, and fastener selection apply their own
specifications.
Bolting is a standard fastening method, for instance, but welding may cut down the weight of
assemblies. Naturally, joints intended for the two approaches would differ tremendously.

However, all joint patterns must consider features such as load factors, assembly effectiveness,
operating surroundings, overhaul and upkeep, and the materials chosen.
Welding is generally a cost-effective approach to fabricate. It doesn't require overlapping
materials, and so it removes excess weight brought on by other fastening methods. Fasteners
don't have to be purchased and stored in stock. Welding also can minimize costs related to extra
parts, for example angles mounted between parts.
Advantages of mechanical joining

 No thermal structural transformation of work pieces

 Numerous choice of material of rivets, sizes, forms etc.
 High strength capacity
 Mobility of material after joining
 Easy to control quality
 Good environmental behavior – no emission or polution

Disadvantages of mechanical joining

 Can be difficult or impossible to repair joints

 Many rivets are patented and may mean higher cost

Mechanical joining Mechanical energy

 Riveting
 Caulking
 Bolting
 Shrink fitting
 Folding

Chemical joining Chemical energy

 Bonding

Metallurgical joining (welding) Fusion welding Electrical energy

 Arc welding
 Electron beam welding

Chemical energy
 Gas welding

Light energy
 Laser welding
Joining includes welding, brazing, soldering, adhesive bonding of materials. • They produce
permanent joint between the parts to be assembled. • They cannot be separated easily by
application of forces.

MOULDING/MOLDING
What is molding?
Molding or moulding is the process of manufacturing by shaping liquid or pliable raw material
using a rigid frame called a mold or matrix. This itself may have been made using a pattern or
model of the final object.
A mold or mould is a hollowed-out block that is filled with a liquid or pliable material such
as plastic, glass, metal, or ceramic raw material. The liquid hardens or sets inside the mold,
adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding
process uses two molds, one for each half of the object. 
Articulated moulds have multiple pieces that come together to form the complete mold, and then
disassemble to release the finished casting; they are expensive, but necessary when the casting
shape has complex overhangs.
Piece-molding  uses a number of different molds, each creating a section of a complicated
object. This is generally only used for larger and more valuable objects.

MOLDING TECHNOLOGIES AND TECHNIQUE

Die cast moulding is a metal casting process. It typically forces molten metal – either zinc,
copper, aluminium, magnesium, lead, pewter, or tin-based alloys – under high pressure into a
mould cavity. This cavity is created using two hardened steel dies that have been machined into
shape, working in a manner similar to a plastic injection mould. Most die-castings are made of
non ferous
METAL MOULDING PROCESSES
Metal injection molding (MIM) is a metalworking process in which finely-powdered metal is
mixed with binder material to create a "feedstock" that is then shaped and solidified
using injection molding. The molding process allows high volume, complex parts to be shaped in
a single step. After molding, the part undergoes conditioning operations to remove the binder
(debinding) and densify the powders. Finished products are small components used in many
industries and applications.

POROSITY OR PERMEABILITY
It is the property of sand which permits the steam and other gases to pass through the sand
mould. The porosity of sand depends upon its grain size, grain shape, moisture and clay
components are the moulding sand. If the sand is too fine, the porosity will be low.

Plasticity

It is that property of sand due to which it flows to all portions of the moulding box or flask. The
sand must have sufficient plasticity to produce a good mould.
Adhesiveness

It is that properties of sand due to it adheres or cling to the sides of the moulding box. 4:
Cohesiveness It is the property of sand due to which the sand grains stick together during
ramming. It is defined as the strength of the moulding sand.

Refractoriness

The property which enables it to resist high temperature of the molten metal without breaking
down or fusing.

Classification of Moulding sand according to their use:

Green sand

The sand in its natural or moist state is called green sand. It is also called tempered sand. It is a
mixture of sand with 20 to 30 percent clay, having total amount of water from 6 to 10 percent.
The mould prepared with this sand is called green sand mould, which is used for small size
casting of ferrous and non-ferrous metals.

Dry Sand

The green sand moulds when baked or dried before pouring the molten metal are called dry sand
moulds. The sand of this condition is called dry sand. The dry sand moulds have greater strength,
rigidity and thermal stability. These moulds used for large and heavy casting.

Loam Sand

A mixture of 50 percent sand grains and 50 percent clay is called loam sand. It is used for loam
moulds of large grey iron casting.

Facing Sand

A sand which is used before pouring the molten metal, on the surface is called facing sand. It is
specially prepared sand from silica sand and clay.

Backing or Floor Sand

A sand used to back up the facing sand and not used next to the pattern is called backing sand.
The sand which have been repeatedly used may be employed for this purpose. It is also known as
black sand due to its colour.

System Sand A

sand employed in mechanical sand preparation and handling system is called system sand. This
sand has high strength, permeability and refractoriness
Parting Sand

A sand employed on the faces of the pattern before the moulding is called parting sand. The
parting sand consists of dried silica sand, sea sand or burnt sand.

Core Sand

The cores are defined as sand bodies used to form the hollow portions or cavities of desired
shape and size in the casting. Thus the sand used for making these cores is called core sand. It is
sometimes called oil sand. It is the silica sand mixed with linseed oil or any other oil as binder.

MACHINING

Machining is any of various processes in which a piece of raw material is cut into a desired final
shape and size by a controlled material-removal process. The processes that have this common
theme, controlled material removal, are today collectively known as subtractive manufacturing,
in distinction from processes of controlled material addition, which are known as additive
manufacturing. Exactly what the "controlled" part of the definition implies can vary, but it
almost always implies the use of machine tools (in addition to just power tools and hand tools).
Machining is a part of the manufacture of many metal products, but it can also be used on
materials such as wood, plastic, ceramic, and composites.
A person who specializes in machining is called a machinist.
A room, building, or company where machining is done is called a machine shop.
Much of modern-day machining is carried out by computer numerical control (CNC), in which
computers are used to control the movement and operation of the mills, lathes, and other cutting
machines.

Different Machining Processes

During the manufacturing of a part, a variety of processes are needed to remove excess material.
Three primary machining processes—turning, drilling, and milling—are used as a means of
removal. Each process plays a key role in how a product is manufactured and enhances each
product’s unique properties.

Turning CNC lathe cutting metal

Turning is a machining process performed by a device called a lathe; the lathe spins the given
product as the blades cut and scrape away the desired areas. The cutting tools work along two
axes of motion to create cuts with precise depth and diameter. Lathes are available in two
different types, the traditional, manual type and the automated, computer numerical controlled
(CNC) type. The turning process can be performed on either the exterior or interior of a material.
When performed on the inside, it is known as "boring”—this method is most commonly applied
to create tubular components. Another part of the turning process is called "facing” and occurs
when the cutting tool moves across the end of the work piece—it is typically performed during
the first and last stages of the turning process. Facing can only be applied if the lathe features a
fitted cross-slide. Lathes are generally identified as one of three different sub-types -- turret
lathes, engine lathes, and special purpose lathes. Engine lathes are the most common type found
in use by the general machinist or hobbyist. The term "engine" is used to differentiate it from
other lathes that are either foot- or hand-powered. Turret lathes and special purpose lathes are
more commonly used for applications that require repeated manufacturing of parts. Turret lathes
feature a tool holder that enables the machine to perform a number of cutting operations in
succession without interference from the operator.
Drilling

Drilling occurs when cylindrical holes are produced in a piece of solid material using a drill bit—
it is one of the most important machining processes as the holes that are created are often
intended to aid in assembly—to ensure stability and precision, a drill press is often used. The
drill bits used feature two spiral channels that run up the shaft of the bit. Known as the "fluting,"
it carries the chips, or swarf, out of the hole as the bit progresses into the piece of material. For
each type of material, there is a recommended drill speed and feed. cnc milling machine working
steel
Milling

Milling is another process that uses rotating cutters to remove material, but the difference lies in
how the equipment works. A milling machine features a moveable table on which the material is
mounted. In most milling machines, the cutting tools are stationary and the table moves the
material so that the desired cuts can be made. Other types of milling machines feature both table
and cutting tools as moveable implements. Some of the operations a milling machine is capable
of performing include planing, cutting, rebating, routing, die-sinking and other complex tool-
paths, making the milling machine one of the more flexible pieces of equipment in a machine
shop. Milling machines offer versatile operations and maintenance is low-cost; since they
generally have a long and glitch-free life, the investment return is high. There are four types of
milling machines—hand milling machines, plain milling machines, universal milling machines,
and omniversal milling machines—and they feature either horizontal cutters or cutters installed
on a vertical axis.. As expected, the universal milling machine allows for both vertical and
horizontal mounted cutting tools, making it one of the most complex and flexible milling
machines available.

Grinding
Grinding process is used for improving the finish of the surface and tightening up the tolerance
by removing the remaining unwanted materials from the surface. Grinding machines are used for
this purpose to produce parts of identical shape, size and finish. Grinding operation Chip
Formation In chip formation process materials are cut through mechanical means by using tools
like milling cutters, saws and lathes. It is an integral part of the engineering of developing
machines and cutting tools.
WELDING PROCESS AND EQUIPMENT
What is WELDING?

Is a metallurgical joining process with applying many types of heat source.

Is the joining processes are classified on a basis of joining mechanism and energy source.
Classification of joining method of metals

Electrical Energy
(Metallurgical joining)

Fusion Welding

Arc Welding
It is a process of welding that uses arc heat to melt a workpiece to be welded.
A technique in which metals are welded using heat generated by an electric arc.
Arc Welding is one of several fusion processes for joining metals. By applying intense heat,
metal at the joint between two parts is melted and caused to intermix. Arc Welding is the most
popular welding style. An electric arc is created between metal and an electrode, forming a
puddle where filler metal can be added.

Electro slag welding

Is a highly productive, single pass welding process for thick (greater than 25 mm up to about 300
mm)
materials in a vertical or close to vertical position materials in a vertical or close to vertical

position.

Electron-beam welding
is a fusion welding process in which a beam of high-velocity electrons is applied to two materials
to be joined.
The work piece melt and flow together as the kinetic energy of the electrons is transformed into
heat upon impact.
Pressure Welding

Resistance welding
Electric resistance welding (ERW) refers to a group of welding processes such as spot and seam
welding that produce coalescence of faying surfaces where heat to form the weld is generated by
the electrical resistance of material combined with the time and the force used to hold the
materials together during welding.

Upset welding
is a welding technique that produces coalescence simultaneously over the entire area of abutting
surfaces or progressively along a joint, by the heat obtained from resistance to electric current
through the area where those surfaces are in contact.[1] . Pressure is applied before heating is
started and is maintained throughout the heating period.

Flash welding
is a type of resistance welding that does not use any filler metals. ... Current is applied to the
metal, and the gap between the two pieces creates resistance and produces the arc required to

melt the metal.

Chemical Energy
Metallurgical joining

Gas welding
process is quite simpler compare to arc welding. In this process all the equipment are connected
carefully. The gas cylinder and oxygen cylinder
connected to the welding torch through pressure regulators.

Thermite Welding
is a liquid state welding process in which the metal to metal joint created by melting of base
material or applying filler material in liquid form.

Explosion welding
is a solid state (solid-phase) process where welding is accomplished by accelerating one of the
components at extremely high velocity through the use of chemical explosives.
Torch brazing
is a procedure where the heat is applied using a gas flame placed on or near the joint being
brazed.

Mechanical Energy

Pressure Welding

Cold pressure welding

is a solid-state welding process in which joining takes place without fusion/heating at the
interface of the two parts to be welded.

Friction welding (FRW)

is a solid-state welding process that generates heat through mechanical friction between
workpieces in relative motion to one another, with the addition of a lateral force called "upset" to
plastically displace and fuse the materials.
Friction stir welding (FSW)
is a solid-state joining process that uses a non-consumable tool to join two facing workpieces
without melting the workpiece material. Heat is generated by friction between the rotating tool
and the workpiece material, which leads to a softened region near the FSW tool.

Ultrasonic welding
is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally
applied to work pieces being held together under pressure to create a solid-state weld.

Diffusion bonding or diffusion welding

is a solid-state welding technique used in metalworking, capable of joining similar and dissimilar
metals. Diffusion bonding is usually implemented by applying high pressure, in conjunction with
necessarily high temperature, to the materials to be welded; the technique is most commonly
used to weld "sandwiches" of alternating layers of thin metal foil, and metal wires or filaments.

Optical Energy
Metallurgical joining
Laser beam welding (LBW)
is a welding technique used to join pieces of metal or thermoplastics through the use of a laser.
The beam provides a concentrated heat source, allowing for narrow, deep welds and high
welding rates. The process is frequently used in high volume applications using automation, such
as in the automotive industry.
TYPICAL WELD JOINT

Manual Metal Arc Welding (MMAW)

Manual metal arc welding is a metal arc welding process (MMAW) in which an electrical arc
burns between a sheathed rod electrode and the material. No shielding gas is used in manual
metal arc welding. The sheathed melting electrode forms a shielding gas to protect the smelt and
supplies additives to create the required seam. Manual metal arc welding can be used on nearly
all materials suitable for welding, simply and efficiently. Shielding gas is not supplied but is
created – depending on the requirement and material – when the electrode sheath melts. The
procedure is also used in small and medium-sized businesses and when building ships, pipelines
as well as steel constructions and bridges outdoors.
Submerged Arc Welding (SAW)
Submerged arc welding is commonly used in industries where thick steel sheets are involved or
where long welds are required. The process consists in creating a welded joint between steel
components using an electric arc submerged beneath a layer of powdered flux. Submerged-arc
welding (SAW) involves the formation of an arc between a continuously fed wire and the
workpiece. A blanket of powdered flux creates a protective gas shield and a slag for the weld
zone. A shielding gas is not required. The arc is submerged beneath the flux blanket and is not
normally visible during welding.

Gas Shielded Arc Welding (GMAW)

An electric current, in the form of either alternating current or direct current from a welding
power supply, is used to form an electric arc between the electrode and the metals to be joined.
The workpiece and the electrode melts forming a pool of molten metal (weld pool) that cools to
form a joint. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors
that serve as a shielding gas and providing a layer of slag, both of which protect the weld area
from atmospheric contamination.
Non-Consumable Electrode Welding

TIG Welding (TIG)

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an
arc welding process that uses a non-consumable tungsten electrode to produce the weld. The
weld area and electrode is protected from oxidation or other atmospheric contamination by an
inert shielding gas (argon or helium). GTAW is most commonly used to weld thin sections of
stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys.

Plasma Arc Welding (PAW)

Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding
(GTAW). The electric arc is formed between an electrode (which is usually but not always made
of sintered tungsten) and the workpiece. The key difference from GTAW is that in PAW, by
positioning the electrode within the body of the torch, the plasma arc can be separated from the
shielding gas envelope. The plasm is then forced through a fine-bore copper nozzle which
constricts the arc and the plasma exits the orifice at high velocities (approaching the speed of
sound) and a temperature approaching 28,000 °C (50,000 °F) or higher. Just as oxy-fuel torches
can be used for either welding or cutting, so too can plasma torches, which can achieve plasma
arc welding or plasma cutting.
Consumable Electrode Welding

MAG Welding
This type of welding is frequently used to make vehicles, vessels and pipes as well as in
mechanical engineering. Even in shipbuilding, it is difficult to image life without MAG welding.
As, due to the fast welding speed, little deformation is to be expected, even in difficult or
awkward positions, this arc welding procedure is primarily used for repairs and maintenance of
thin metal sheets from 0.6mm thick. The weld is high-strength. Therefore almost no rework is
necessary. The weld is protected against oxidation. No slag is produced. The working speed is
very high. The result is lower heat effects of the surrounding material. This procedure can be
used in all Welding positions.

CO2 Arc Welding

the welding wire wound in coil is fed into the welding torch by the feeding motor automatically.
The welding wire that is electrified through the contact tip becomes the electrode to strike an arc
between itself and the base metal. The arc heat melts the wire and the base metal to join two
pieces of base metal. In this case, in order that the weld metal will not be affected by oxygen and
nitrogen in the atmosphere, CO2 gas is supplied from the nozzle of the welding torch to shield
the weld pool.
Mixed Gas Shielded Arc Welding
MAG welding uses a mixture of argon with an active gas such as oxygen, CO2 or both.
Each of the various components of shielding gases has its own effect. The components are
combined with precision for optimal effect.
The variety of shielding gases used in arc welding can be a confusing topic. However, the use of
an external shielding gas is a necessary component for some processes, as it is a requirement for
surrounding and protecting the arc and molten weld metal from contamination by the
atmosphere. Shielding gas can also increase the smoothness of the arc and operator appeal.

SHEET PRESS OR TOOL AND DIE PROCESS

A die is a specialized tool used in manufacturing industries to cut or shape material mostly using
a press. Like molds, dies are generally customized to the item they are used to create. Products
made with dies range from simple paper clips to complex pieces used in advanced technology
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the
sheet metal components in large volumes. Generally press tools are categorized by the types of
operation performed using the tool, such
as blanking,piercing, bending, forming, forging, trimming etc. The press tool will also be
specified as a blanking tool, piercing tool, bending tool et
 Forming press, commonly shortened to press, is a machine tool that changes the shape of a
workpiece by the application of pressure.[1] The operator of a forming press is known as a press-
tool setter, often shortened to toolsetter.
Presses can be classified according to

 their mechanism: hydraulic, mechanical, pneumatic;
 their function: forging presses, stamping presses, press brakes, punch press, etc.
 their structure, e.g. Knuckle-joint press, screw press
 their controllability: conventional vs. servo-presses